From Sketch to Shelf: 5 Stages of the Product Design Process
- Matthew Bowman
- Feb 3
- 2 min read
Bringing a new product to market is an exciting journey. However, for many entrepreneurs and businesses, the path from a "lightbulb moment" to a physical object can feel like a confusing journey into the unknown. As a freelance product designer, my job is to help navigate that complexity.
At the start of a project I'm often asked to breakdown the design process and explain what will be delivered at each stage.
For this blog post I’ve done something similar and broken down the professional design workflow into five essential stages. Whether it's a perfume bottle or a children's toy, this structured process ensures the final result is functional, aesthetically pleasing, and most importantly, manufacturable.
1. Discovery & Research
Before a single line is drawn, we have to understand the why. This stage is about identifying the problem we are solving. We look at:
User Needs: Who is going to be using the product and what are their pain points?
Market Analysis: What do competitors do well, and where do they fail?
Constraints: These often include things like target retail price, safety regulations and material suitability.
2. Concept Generation
This is the most creative part of the process. Using concept sketching, I explore a wide variety of forms and mechanical solutions. We don't just pick the first idea; we iterate. This stage allows us to fail fast and cheaply on paper before committing to expensive digital development.
3. Design Development (3D CAD)
Once a concept is chosen, we move into CAD (Computer-Aided Design). This is where the product starts to take on "real" dimensions. We define wall thicknesses, internal components, and how different parts snap or screw together. These digital models are the blueprints that will eventually be sent to factories.
4. Prototyping & Testing
A design might look perfect on a screen, but you can’t truly understand ergonomics until you hold it. Using 3D printing and workshop models, we test the physical reality of the design. Does it fit comfortably in the hand? Is the assembly intuitive? We use these insights to "loop back" and refine the CAD model.
5. Final Specification
The final stage is preparing the Manufacturing Package. This includes final 3D files and 2D technical drawings with tolerances and material specifications. This is the "language" that manufacturers speak, ensuring that the factory, whether in Sheffield or anywhere else in the world, builds exactly what we design.
Why This Process Matters
Skipping stages might seem like a way to save time, but it usually leads to expensive "firefighting" during production. A structured process minimises risk and ensures that when your product finally hits the shelf, it’s exactly as you envisioned.
Ready to start your journey from sketch to shelf? If you have a product idea and need a designer to help navigate these stages, I’d love to hear from you. Based in Sheffield, I work with clients across the UK and further afield to turn concepts into reality.
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